High strength corrugated carton design and lid for modified atmosphere packaging of fresh produce and fresh-cut flowers

ABSTRACT

A container assembly including, a carton base having a substantially planar bottom surface, a lid having a top surface and a plurality of sidewalls extending therefrom. The lid is releasably engaged with the carton base and forms an interior space when engaged with the carton base. The top surface of the lid includes: a plurality of raised platforms, each raised platform having a substantially planar top surface, and a plurality of channels extending between each of the raised platforms such that each of the plurality of channels continuously extends to a perimeter of the lid. Additionally, the carton base is formed of three distinct laminate layers, with at least one of the laminate layers including a resin and a board weight of 200 g/m2 to 300 g/m2.

BACKGROUND Cross-reference to Related Applications

This application is a continuation of PCT International Patent Application No. PCT/US2020/014171 filed on Jan. 17, 2020, which claims priority to U.S. Provisional Application No. 62/793,559 filed on Jan. 17, 2019, the entirety of each of which is incorporated by this reference.

Field of the Invention

The present invention relates generally to reusable containers used to transport goods in modified atmospheric conditions, specifically goods such as vegetables, fruit, flowers and plants.

State of the Related Art

The use and manufacture of containers to transport produce, flowers and plants is an old and well-known art. Corrugated Paper Cartons (CPC), both waxed and unwaxed, and Reusable Plastic Containers (RPC) have been used to transport produce in ambient atmospheres. RPC conventionally rely extensively on a porous construction to provide cooling of the goods housed therein, such as produce, which often desiccates the produce, resulting in shrink and loss of postharvest distribution and shelf life of the produce.

As an alternative to CPC and RPC, Modified Atmosphere Packaging (MAP) has been used in an attempt to better prevent produce loss by reducing water loss, produce respiration, and in some cases decay, through the application and utilization of active antimicrobials. However, the use of active antimicrobials can pose other problems and expenses related to potential contamination and storage and use of active antimicrobial inventory.

In conventionally used CPC, RPC and MAP products, container damage is also often a chief concern, as during shipping, transit, and/or storage, these products are often stacked one on top of another, on pallets or on floors. In these situations the container products endure, sometimes significant, structural stresses that can cause failure of the containers, which can result in a total loss of goods stored within the damaged containers.

The use of modified atmosphere packaging can actually extend the useful distribution and shelf life by about 4 to 5 times that of produce packed in conventional corrugated cartons. With extended cool chain transportation that is often used to ship produce or other product, the shipping cartons are typically subject to high relative humidity that reduces the structural strength of the cartons. In addition, transport of these cartons, either by road, rail or ocean carriers, can subject the produce and the cartons to lateral and vertical forces which reduce the strength of the cartons. The current cartons are not designed to sustain the vertical weight bearing over a long, cool chain transportation.

Thus, there exists a need in the art to provide a reusable container which utilizes modified atmospheric packaging to better preserve the quality goods, such as, produce, flowers and plants, after transport. The present application provides for a high strength container design for modified atmosphere packaging of quality goods, such as, produce, flowers and plants, before, during and after transport.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a container assembly includes, a carton base having a substantially planar bottom surface, a lid having a top surface and a plurality of sidewalls extending therefrom. The lid is releasably engaged with the carton base and forms an interior space when engaged with the carton base. The top surface of the lid includes: a plurality of raised platforms, each raised platform having a substantially planar top surface, and a plurality of channels extending between each of the raised platforms such that each of the plurality of channels continuously extends a perimeter of the lid. Additionally, the carton base may be formed by corrugation of three distinct layered laminates to the medium (flute), with at least one of the laminate layers including a resin and a laminate weight of 200 g/m² to 300 g/m².

In another embodiment of the invention, a plurality of containers may be stacked vertically on one another.

These and other aspects of the present invention may be realized in an improved container assembly as shown and described in the following figures and related description.

BRIEF DESCRIPTION OF THE DRAWINGS

When considered in connection with the following illustrative figures, a more complete understanding of the present invention may be derived by referring to the detailed description. In the figures, like reference numbers refer to like elements or acts throughout the figures. Various embodiments of the present invention are shown and described in reference to the numbered drawings.

FIG. 1 is a perspective view of a container in accordance with the principles of the present invention;

FIG. 2 is a side view the container shown in FIG. 1;

FIG. 3 is a side cross-sectional view of the container shown in FIG. 1;

FIG. 4A is a magnified side view of the container shown in FIG. 1;

FIG. 4B is a magnified side view of a liner shown in FIG. 4A

FIG. 5 is a side view of two disclosed containers stacked vertically;

FIG. 6 is a top view of another embodiment of a container in accordance with the principles of the present invention;

FIG. 7 is a side cross-sectional view of the container shown in FIG. 6;

FIG. 8 is a top view of a carton base of the container shown in FIG. 5; and

FIG. 9 is a top view of carton base sheet, prior to assembly.

It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention, which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity. Similarly, not every embodiment need accomplish all advantages of the present invention. Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The invention and accompanying drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The drawings and descriptions are exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. It is noted that the inventor can be his own lexicographer. The inventor expressly elects, as his own lexicographer, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventor's intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.

Further, the inventors fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description of the Invention or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for” and the specific function (e.g., “means for filtering”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for . . . ” or “step for . . . ” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventor not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the illustrated embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.

In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. Thus, the full scope of the inventions is not limited to the examples that are described below.

FIGS. 1-4 illustrate a container 100 which may include a carton base 102 and a lid 104 which can be engaged to and seal an interior space within the carton base 102. The carton base 102 and lid 104 may be configured to utilize a water vapor barrier construction and the carton base 102 may be formed or manufactured from a corrugated material. Furthermore, additional material may be added to the corrugated material of the carton base which resists water transfer and absorption by the corrugated material.

The carton base 102 may be formed as box having a substantially planar bottom surface 102 a, and a plurality of sidewalls 102 b extending upwardly therefrom. The carton base 102 may alternatively include individualized compartments or sections that may be customizable in shape and size depending on the products to be stored and shipped therein. The carton base 12 may also be formed having a quadrilateral cross-sectional shape, such as a rectangle, as shown in FIGS. 1-5, or in any other desired shape. The carton base 102 may also be configured to both protect and insulate products stored within the container 102, from the ground and/or floor environment and elements such as extreme temperatures, moisture, or substantially arid climates which may cause the products to dry out.

The lid 104 of the container 100 may be configured to create a seal when connected or secured to the carton base 102, forming a sealed interior space. The lid 104 may be of any known transparent or colored material that can also provide a water vapor barrier. The lid 102 may also be formed of, at least in part, a permeable material that can regulate the atmospheric conditions within the container 100. The seal formed by the lid 104 and the carton base 102 may be a liquid-tight seal and/or an air-tight seal, thus preserving and maintaining a specific desired environment within the container 100. The lid 104 may be formed having a quadrilateral cross-sectional shape, such as a rectangle, as shown in FIGS. 1-4A, or in any other desired shape. The lid 104 may include sealing protrusions 106 that may extend from an interior surface of each of the corners of the lid 104. These protrusions 106 may then actively engage with a corresponding outer surface of the carton base 102, thereby forming a seal. The engagement between the protrusions 106 and carton base 102 may be a friction fit, snap fit, taped or glued or any other desired engagement that may facilitate an air-tight and/or water-tight seal between the carton base 102 and the lid 104.

The lid 104 may include a plurality of sidewalls 108, such as the four sidewalls 108 shown in FIG. 1, and a stop surface 110. Each of the sidewalls 108 may extend from the top surface 110 in a tapered, non-perpendicular direction, such that the sidewalls 108 are not squared, or at 90 degrees, from the top surface 110. These tapered sidewalls 108 can provide easier removal from a fabrication mold, for example, and may also allow multiple lids 104 to be stacked in an overlapping manner during storage or shipping of the lids 104 when not engaged with corresponding carton bases 102.

The top surface 110 of the lid 104 may include a plurality of raised platforms 112. The raised platforms 112 may include substantially planar, or planar, top surfaces 112 a. Each of the top surfaces 112 a may also be coplanar, or substantially coplanar, with one another, thereby providing a series of substantially flat, planar surfaces that can provide a foundation for stacking multiple cartons 100 on top of one another. The raised platforms 112 may be evenly and symmetrically spaced from one another. As shown in FIG. 5, by having each of the top surfaces 112 a being substantially coplanar, and symmetrically spaced apart, the raised platforms 112 can provide a strong, stable foundation for a second carton 100 stacked thereon. Therefore, the present carton base 102 and lid 104 configuration provide a greater load bearing surface by multiple points of contact, via the raised platforms 112, supporting multiple cartons in a vertical stacked configuration.

The top surface 110 may also include a series of flow passages 114, or channels, dividing each of the raised platforms 112 from one another. These flow passages 114 may be continuous throughout the top surface 110 such that each flow passage may extend to an outer perimeter of the lid 104. This flow passage configuration can provide ample air flow between stacked containers 100, as shown in FIG. 5. By providing ample air flow between stacked containers 100, the temperature of each container 100 may be more easily regulated when stacked, for example, on a pallet. Keeping each stacked container 100 individually cooled can be imperative in preserving the integrity of certain products stored within the containers 100, such as plants and produce, for example.

The carton base 102 and lid 104 may be formed from any desired material, such as plastic, cardboard, resin, or any other composite or desired material, and may be opaque or transparent. However, the present carton base 102 may also be formed using three distinct layered laminates, 120, 121, and 122, combined as a single liner 152, as shown in FIG. 4B. A cardboard base layer 150 may be used as the main structure of the carton base 102, however, the liner 152 may be bonded to an interior surface of the cardboard base layer 150, or to an exterior surface of the cardboard base layer 150, or both the interior and exterior surfaces, as shown in FIG. 4A. It should be noted that the cardboard layer 150 and liner 152 are not illustrated to scale in FIGS. 4A, 4B or FIG. 7 (discussed in more detail below), and are simple shown schematically to show their relative positioning and use.

The liner 152 may have a board weight of 200 g/m² to 300 g/m², for example, and may also include a range of individual resins including: PETE, polypropylene, nylon, and/or combinations or mixtures thereof, or additional types of resins that may provide a water vapor barrier. The three layers 120, 121, and 122, also called a linerboard, can then be bonded together using a laminate process or any other desired bonding process known in the art. Having the liner 152 bonded to a cardboard base layer 150 can provide the requisite strength to maintain the structural integrity of carton base 102, while also maintaining a relatively light weight and flexibility, particularly during shipping or transport.

FIGS. 6-8 illustrate another container embodiment. Container 200 may include a carton base 202 and a lid 204 which can be engaged to and seal an interior space within the carton base 202. The carton base 202 and lid 204 may be configured to utilize a water vapor barrier construction and the carton base 202 may be formed or manufactured from a corrugated material. Furthermore, additional material, or a linerboard or liner, may be added to the corrugated material of the carton base which resists water transfer and absorption by the corrugated material.

The carton base 202 may be formed as a box having a substantially planar bottom surface 202 b, and a plurality of sidewalls 202 a extending upwardly therefrom. As shown in FIG. 8, in each corner of the carton base 202 a folded double layer 220 a, 220 b, 220 c, 220 d, may be formed. These folded double layers may be formed during assembly of the container base 220 and may provide significant additional structural support to the integrity of the carton base 202. Each folded double layer 220 a, 220 b, 220 c, 220 d, may extend substantially diagonally across each corner of the container base 202 and extend from an interior bottom surface of the carton base 202 to a terminating end of the adjacent sidewalls 202 a. Each of the folded double layers 220 a, 220 b, 220 c, 220 d, may be composed of the same material or combination of materials as the sidewalls 202 a and the “folded” design of these layers not only increases the structural strength of the carton base 202, but it improves assembly time, as additional material pieces are not needed to form the folded double layers 220 a, 220 b, 220 c, 220 d.

Referring to FIG. 9, each of the sidewalls 202 a of the carton base include at least one or more scallops 203, or cutout portions, at a terminating end of each sidewall 202 a. As illustrated, the scallops 203 may be curved, but may also have any other desired shape, such as semicircular, rectangular, square, or triangular, for example. On each side of each scallop 203, along the terminating end of the respective sidewalls 202 a are substantially planar support surfaces 205. As shown in FIG. 7, each scallop 203 is configured to receive a corresponding flow passage 214 (discussed in more detail below) formed in the lid 204 and each support surface 205 abuts an undersurface of a corresponding raised platform 212 (discussed in more detail below) formed in the lid 204. Accordingly, the support surfaces 205 may add significant structural and vertical support around the perimeter of the lid 204. This added structural support may be particularly important as containers 200 are stacked vertically, which can significantly increase the loads on the lids 204 and the cartons bases 202.

Similarly to container 100 discussed above, carton base 202 may be formed using the three distinct layer laminates, 120, 121, and 122, combined as a single liner 152, as shown in FIG. 4B. A cardboard base layer 250 may be used as the main structure of the carton base 202, however, the liner 152 may be bonded to an interior surface of the cardboard base layer 250, or to an exterior surface of the cardboard base layer 250, or both the interior and exterior surfaces, as shown in FIG. 4A. It should be noted that the cardboard layer 250 and liner 152 are not illustrated to scale in FIG. 7 and are simply shown schematically to show their relative positioning and use.

The carton base 202 may alternatively include individualized compartments or sections that may be customizable in shape and size depending on the products to be stored and shipped therein. The carton base 202 may also be formed having a quadrilateral cross-sectional shape, such as a rectangle, as shown in FIGS. 7 and 8, or in any other desired shape. The carton base 202 may also be configured to both protect and insulate products stored within the container 202, from the ground and/or floor environment and elements such as extreme temperatures, moisture, or substantially arid climates which may cause the products to dry out.

The lid 204 of the container 200 may be configured to create a seal when connected or secured to the carton base 202, forming a sealed interior space. The lid 204 may be of any known transparent or colored material that can also provide a water vapor barrier. The lid 204 may also be formed of, at least in part, a permeable material that can regulate the atmospheric conditions within the container 200. The seal formed by the lid 204 and the carton base 202 may be a liquid-tight seal and/or an air-tight seal, thus preserving and maintaining a specific desired environment within the container 200. The lid 204 may also secured and sealed to the carton base 202 with the use of tape 230. The tape 230, as shown in FIG. 7, can overlap a portion of the carton base 202 and the lid 204, continuously around the entire perimeter of the container 200. The tape 230 may not only provide or improve the seal between lid 204 and the carton base 202, the tape 230 may also increase the structural strength of the container 200.

The lid 204 may be formed having a quadrilateral cross-sectional shape, such as a rectangle, as shown in FIGS. 6 and 7, or in any other desired shape. The lid 204 may include a plurality of sidewalls 208, and a top surface 210. Each of the sidewalls 208 may extend from the top surface 210 in a tapered, non-perpendicular direction, such that the sidewalls 208 are not squared, or at 90 degrees, from the top surface 210. These tapered sidewalls 208 can provide easier removal from a fabrication mold, for example, and may also allow multiple lids 204 to be stacked in an overlapping manner during storage or shipping of the lids 204 when not engaged with corresponding carton bases 202.

The top surface 210 of the lid 204 may include a plurality of raised platforms 212. The raised platforms 212 may include substantially planar, or planar, top surfaces 212 a. Each of the top surfaces 212 a may also be coplanar, or substantially coplanar, with one another, thereby providing a series of substantially flat, planar surfaces that can provide a foundation for stacking multiple cartons 200 on top of one another. The raised platforms 212 may be evenly and symmetrically spaced from one another.

The top surface 210 may also include a series of flow passages 214, or channels, dividing each of the raised platforms 212 from one another. These flow passages 214 may be continuous throughout the top surface 210 such that each flow passage may extend to an outer perimeter of the lid 204. This flow passage configuration can provide ample air flow between stacked containers 200. By providing ample air flow between stacked containers 200, the temperature of each container 200 may be more easily regulated when stacked, for example, on a pallet. Keeping each stacked container 200 individually cooled can be imperative in preserving the integrity of certain products stored within the containers 200, such as plants and produce, for example.

Additionally, to further improve the internal climate of the container 200, the lid 204 may include a ventilation surface 240, which may include a plurality of ventilation holes 240 a. The ventilation surface 240 may be countersunk from the raised platforms 212, to ensure that the ventilation holes 240 a are not closed off if multiple containers 200 are stacked on top of one another. A permeable, anti-microbial sheet, or sachet, 242 may be positioned on the ventilation surface 240 as a mechanism for reducing the possibility of contamination of products within the container 200. A film seal 244 may then be placed and secured above the ventilation surface 240 onto a seal surface 246. The film seal 244 can then be used to retain and seal the anti-microbial sheet 242 in place above the ventilation holes 240 a during use and transport.

Referring to FIG. 9, carton base 202 may be manufactured as a single sheet 300. Each cut line 302 of the sheet 300 may be cut, to enable folding and the erecting of the carton base 202. Each fold line 304 represents a scored line to be folded during assembly, where a user or manufacturer may fold the sheet 300 to form the carton base 202. After the cuts have been made along cut lines 302, each sidewall 202 a may be folded along the corresponding fold lines 304 to a substantially vertical position with respect to the bottom surface 202 b. Then each of the folded double layer corners 220 a, 220 b, 220 c, and 220 d may be folded along corresponding fold lines 304 to form the folded double layer configuration shown in FIG. 8. Once all of the folds and cuts have been made, glue can be applied to the glue sections 306 such that the glue sections 306 may be adhered to the corresponding immediately adjacent sidewall 202 a, as shown in FIG. 8. Other adhesive, bonding or attachment mechanisms may also be used instead of glue, depending on need or preference.

In an exemplary embodiment, the laminate layers 120, 121, and 122, or liner 152, the combination of which may also be called a linerboard, may include a first paper layer, such as Kraft Liner Board (KLB), a second paper layer, such as Machined Glaze Bleached Kraft (MGBK), and a resin layer, such as polypropylene, positioned intermediate to the two paper layers. The specifications, such as weight, of this linerboard may be customizable to meet varying needs and demands. For example, the laminate layers may be: KLB 200 g/m², resin 48 g/m², and MGBK 40 g/m² for a total linerboard weight of 288 g/m². In another example, the laminate layers may be: KLB 170 g/m², resin 48 g/m², and MGBK 40 g/m² for a total linerboard weight of 258 g/m². In another example, the laminate layers may be: KLB 127 g/m², resin 48 g/m², and MGBK 57 g/m²for a total linerboard weight of 232 g/m². And in another example, the laminate layers may be: KLB 127 g/m², resin 48 g/m², and MGBK 40 g/m²for a total linerboard weight of 215 g/m².

The linerboard may be tested and quality checked to better ensure performance. Checks using a Sheffield instrument (or Bendtsen) may be taken and recorded prior to a linerboard production run to ensure the smoothest sides, of the paper layers, are on the inside of the laminate adjacent to the polymer layer. Acceptable Sheffield values for the 200 g/m² KLB may be 350-400, and acceptable values for the 40 g/m² MGBK maybe 150-200. To test the coating weight of the linerboard, an average of a minimum of eight 100 mm×100 mm samples may be taken evenly spaced across a text web. A variation of no greater than plus or minus 7% may provide acceptable testing results. During testing of the linerboard, any changes to a coating weight will be subject to this variation factor.

The linerboard may be bonded to a corrugated cardboard base. For example, the linerboard may be bonded to an interior surface of the cardboard base, or a second exterior surface of the cardboard base, or both the interior and the exterior of the cardboard base.

In at least one embodiment, a corrugated cardboard layer bonded with a linerboard may include the following specifications for production. A good adhesive bond between the cardboard and the linerboard is recommended, but not to the point that the board, a combination of the cardboard and linerboard, is too stiff. For example, it is known that a high solids starch with excessive application will produce a board which will crack during the die cutting.

Paper should not be over cooked during the corrugating process otherwise it will likely be too dry and brittle and likely crack on crease lines. It is advisable to wind the linerboard at a double backer heater drum with the KLB layer to the drum surface for two reasons, firstly, the Kraft Linerboard (KLB) is the component which has to be glued to the medium and secondly, it is thicker and therefore takes longer to heat. If the tissue, or MGBK layer, faced the drum surface, it would likely heat more quickly and increase the risk of damaging the polymer or resin layer.

The linerboard preheat drum should be set with a minimum angle of wrap commensurate with producing and adequately bonding a sheet. An acceptable angle of wrap is 25%, although it will depend on the line speed. The linerboard should also be unwound so that the KLB layer is touching the drum surface and not the tissue, or MGBK layer.

The board should be as flat as possible coming off the corrugating line, and to minimize the risk of curl developing in storage, the sheets of board should be reversed on the stack every 20-25. It has been found that steam sprays, present on some corrugating lines, can help minimize the sheet curl without affecting the board moisture content or barrier.

The board may be put to a die cutter within 24 hours of corrugating so that the board is at the optimum temperature and moisture content. If the board is too hot and wet it will not handle well on the press. Similarly, if it is too dry it will be prone to cracking. Stored board sheets have successfully been die-cut when they have been stored under ideal climatic conditions and have been strapped.

A 6pt scoring rule with a flat top and corner radius, may be used to score the board. Narrower rule has a tendency to cut the board and flatter rules may produce a crease line which is too wide. Wave style rule is also not suitable because of its tendency to have many burrs and nip points. It may be necessary to have a very light score so that the linerboard is not stressed to the point of cracking.

Rules may be continuous with no joints on the exposed crease lines. Joints that increase rules can be nip points which cause damage to the liner, so must be avoided. The die must be fastened to the rotary drum or flat bed with adequate securing bolts to ensure the die does not chatter and produce variable depth of crease.

A flat die is generally better to use because it may produce a more dimensionally accurate blank and there is no risk of slippage as the blank goes through the press. With a rotary die there is always the chance that the board could slip as it is fed through the machine and thereby alter the length of the cut. Anvils may also be maintained to a higher standard than for conventional boxes. Ideally, rotary presses with steel anvils may be used but as they are not so common in box plants it may sometimes be necessary to use presses with rubber anvils. Well worn rubber anvils may have severe grooving and this can cause inaccurate creasing, hence the anvils should be replaced more frequently.

To better ensure that the score depth is at the optimum across the whole die it may be necessary to shim certain rules at the back of the rule to raise it. This is particularly the case when the die has crush areas, i.e. cork areas on the die located at the point where flaps overlap on the box. When the board is crushed, any adjacent scores will not be as deep as the rest of the blank so the rule has to be raised.

In a disclosed embodiment a carton base may include folded double wall ends, which may require a special technique of die cutting to ensure the 180 degree fold does not crack the polymer. It is also important that the ends fold squarely to ensure the box assembles squarely.

The die may be made with two crease rules set 6 mm apart with the center filled with either a hard plastic strip or cork. The plastic, or cork, is used to compress the board between the two crease lines and thereby reduce the folding resistance. It is also beneficial to use a CITO channel on the make ready as this improves the definition of the crease. The same technique is also required for the triangular reverse folds on the one-piece easy seal box. It must also be remembered that the end blanks should be fed to the press with the KLB layer facing down, so the crease is applied to the KLB side.

To ensure the disclosed container embodiments perform as designed and control the gas exchange, it is important that hot melt glue, used in constructing the container, is applied correctly to produce an airtight seal. Although the hot glue seal is not truly airtight because of the paper structure, the hot glue seal should nevertheless be made so that there are no macro sized gaps or even capillary pinholes. The glue beads should be continuous.

The hot glue should also be of the correct type. It is important that the glue is selected for the particular method of application; for example, machine application requires a faster setting glue than hand sealing. The glue must also tolerate chilled conditions both during the application stage and the storage. In storage, the glue must retain a good bond to the paper under low temperature, humid conditions and not become brittle. Brittle glues are prone to cracking which would impair the gas barrier and in extreme cases, cause loss of strength. If boxes are pre-erected and stored under ambient conditions prior to use, care must be taken to ensure the glue also withstands such high temperatures otherwise the seals will start opening.

Additional linerboard testing may include pinhole testing, that may be carried out on a sample full width by 1 meter, for example. Prior to applying turpentine, for example, a sheet may be folded both in a machine direction and a cross direction. The turpentine may then be applied to a flat and folded areas. After two minutes, for example, the number of pinholes may be counted and recorded. This check may be carried out at the start of a production run, and every second of liner board roll throughout the production run.

In the event of more than ten pinholes being present on the flat sheet or on the crease line the polymer coating shall be increased to the maximum tolerance setting of plus 7% of the nominal coating weight and rechecked for holes. If the number of pinholes has decreased to ten or less on the flat sheet or the creased lines then the production run shall continue. If the number of pinholes remains the same or has increased then the run shall be aborted.

The linerboard may also have bond strength checks at the start of a production run and at the start of every second roll throughout the run to ensure fiber tearing bonds are achieved. Barrier standards for the disclosed linerboard may include, barrier gas transmission rates standards/specifications (cc/m²/24 hr @ 20° C.) are: 100—O₂, 50—CO₂, ±10 Range.

The three laminate layers 120, 121, and 122 of the carton base 102 may have individually customizable compositions, depending on the use of the container 100 and the type of product being stored in the container 100. For example, the combination of the board weight and the combination of resins can provide a water vapor barrier layer. Such a water vapor layer can be provided as an outside layer, inside layer, middle layer, or any combination thereof. The custom ability of individual layers can also provide flexibility in custom designing the carton for specific densities of produce or products. The construction of the three layers using a combination of corrugate material using such laminates, can increase the strength and integrity of the carton to resist carton collapse, particularly during extended shipping times, which may impose external lateral and vertical stresses that occur during transport. Modified atmospheres are created within the carton which can be customized for specific produce through the sealing procedures in forming the carton.

There is thus disclosed an improved corrugated container and method of manufacturing the container. In the foregoing specification, the present invention has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the spirit and scope of the present invention as set forth in the claims, including combinations of elements of the various illustrated embodiments. The specification and figures are illustrative, not restrictive, and modifications are intended to be included within the scope of the present invention. Accordingly, the scope of the present invention should be determined by the claims and their legal equivalents rather than by merely the examples described.

For example, the steps recited in any method or process claims may be executed in any order and are not limited to the specific order presented in the claims. Additionally, the components and/or elements recited in any apparatus claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims.

Benefits, other advantages, and solutions to problems have been described above with regard to particular embodiments. Any benefit, advantage, solution to problem, or any element that may cause any particular benefit, advantage, or solution to occur or to become more pronounced are not to be construed as critical, required, or essential features or components of any or all the claims.

The phrase “consisting essentially of” as used herein is intended to cover additional elements or functions that do not materially affect the basic and novel characteristics of the claimed invention. Thus, “consisting essentially of” is intended to encompass not only those components specifically listed, but also separate or additional components that do not materially alter the specifically recited functions or elements.

The terms “comprise”, “comprises”, “comprising”, “having”, “including”, “includes” or any variations of such terms, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials, or components used in the practice of the present invention, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters, or other operating requirements without departing from the general principles of the same. 

What is claimed is:
 1. A container assembly, comprising: a carton base having a substantially planar bottom surface; a lid having a top surface and a plurality of sidewalls extending therefrom; wherein the lid is releasably engaged with the carton base and forms an interior space when engaged with the carton base; wherein the top surface of the lid includes: a plurality of raised platforms, each raised platform having a substantially planar top surface, and a plurality of channels extending between each of the raised platforms such that each of the plurality of channels continuously extends to a perimeter of the lid, and wherein the carton base includes a liner, wherein the liner is formed of three distinct laminate layers.
 2. The container assembly of claim 1, wherein at least one of the laminate layers includes a resin.
 3. The container assembly of claim 1, wherein the liner is attached to a cardboard base layer.
 4. The container assembly of claim 1, wherein the liner has a board weight of 200 g/m² to 300 g/m².
 5. The container assembly of claim 1, wherein the carton base includes a plurality of sidewalls, each sidewall having at least one scallop configured to receive a corresponding channel of the lid when the lid is engaged with the carton base.
 6. The container assembly of claim 5, wherein each of the carton base sidewalls includes at least one support surface immediately adjacent to the at least one scallop, wherein the support surface abuts an interior surface of the raised platform of the lid, when the lid is engaged with the carton base.
 7. The container assembly of claim 1, further comprising: a tape layer overlapping and sealing the lid and the carton base when the lid is engaged with the carton base.
 8. The container assembly of claim 1, wherein the lid includes a countersunk surface having a plurality of ventilation holes.
 9. The container assembly of claim 8, wherein the lid includes an antimicrobial sheet secured over the ventilation holes.
 10. A container assembly, comprising: a carton base having a substantially planar bottom surface and a plurality of sidewalls forming an interior space, wherein the plurality of sidewalls of the carton base are formed of a cardboard base layer and a liner attached to an interior surface of the carton base, and wherein the liner includes a resin layer intermediate to two paper layers; a lid having a top surface and a plurality of sidewalls extending therefrom; and wherein the lid is releasably engaged with the carton base and encloses the interior space when engaged with the carton base.
 11. The container assembly of claim 10, wherein the liner has a board weight of 200 g/m² to 300 g/m².
 12. The container assembly of claim 10, wherein the top surface of the lid includes: a plurality of raised platforms, each raised platform having a substantially planar top surface, and a plurality of channels extending between each of the raised platforms such that each of the plurality of channels continuously extends to a perimeter of the lid.
 13. The container assembly of claim 10, wherein a plurality of containers may be stacked vertically on one another.
 14. The container assembly of claim 10, further comprising: a tape layer overlapping and sealing the lid and the carton base when the lid is engaged with the carton base.
 15. The container assembly of claim 10, wherein the liner is also attached to an exterior surface of the carton base.
 16. The container assembly of claim 10, wherein the carton base includes at least one corner adjoining two adjacent sidewalls, wherein at least one of the sidewall is folded to form a double layer at the at least one corner.
 17. The container assembly of claim 10, wherein the lid includes a countersunk surface having a plurality of ventilation holes.
 18. The container assembly of claim 10, wherein the lid includes an antimicrobial sheet secured over the ventilation holes.
 19. The container assembly of claim 12, wherein each sidewall of the carton base having at least one scallop configured to receive a corresponding channel of the lid when the lid is engaged with the carton base.
 20. The container assembly of claim 19, wherein each of the carton base sidewalls includes at least one support surface immediately adjacent to the at least one scallop, wherein the support surface abuts an interior surface of the raised platform of the lid, when the lid is engaged with the carton base. 